Methods for dispensing and compacting insulation materials into a vacuum sealed structure

ABSTRACT

A method of forming an insulated structure for an appliance includes forming a structural enclosure having an outer wrapper and an inner liner and an insulating cavity defined therebetween, forming an insulating powder material, compacting the insulating powder material to form a pre-densified core material, disposing the pre-densified core material within an insulating cavity, wherein the insulating cavity is defined between the outer wrapper and the inner liner and expressing at least a portion of the gas contained within the insulating cavity, wherein the insulating cavity is hermetically sealed to define a vacuum insulated structure.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 14/961,952 filed Dec. 8, 2015, entitled METHODS FOR DISPENSINGAND COMPACTING INSULATION MATERIALS INTO A VACUUM SEALED STRUCTURE, theentire disclosure of which is hereby incorporated herein by reference.

BACKGROUND

This device is in the field of insulating materials for appliances. Morespecifically, this device relates to various methods for dispensing andcompacting insulation material to form a vacuum sealed structure.

SUMMARY

In at least one aspect, a method of forming an insulated structure foran appliance includes forming a structural enclosure having an outerwrapper and an inner liner and an insulating cavity definedtherebetween. An insulating powder material is formed and the insulatingpowder material is compacted to form a pre-densified core material. Thepre-densified core material is disposed within an insulating cavity,wherein the insulating cavity is defined between the outer wrapper andthe inner liner. At least a portion of the gas contained within theinsulating cavity is expressed, wherein the insulating cavity ishermetically sealed to define a vacuum insulated structure.

In at least another aspect, a method of forming an insulated structurefor an appliance includes providing a base formation, wherein a surfaceof the base formation defines a shape of an insulating enclosure. Afirst planar sheet is formed to the surface of the base formation,wherein the first planar sheet includes one of an outer wrapper and aninner liner of an insulating structure. An insulating powder material iscompacted to define a pre-densified core material. The pre-densifiedcore material is positioned in engagement with the first planar sheet. Asecond planar sheet is formed proximate the pre-densified core material,wherein the second planar sheet includes the other of the outer wrapperand the inner liner. The outer wrapper and inner liner are sealedtogether to define an insulating cavity between the outer wrapper andthe inner liner, wherein the pre-densified core material is disposedwithin the insulating cavity. At least a portion of the gas containedwithin the insulating cavity is expressed wherein the insulating cavityis hermetically sealed to define a vacuum insulated structure.

In at least another aspect, a method of forming an insulated structurefor an appliance includes providing a base formation, wherein a surfaceof the base formation defines a shape of an insulating enclosure. Afirst planar sheet is formed to the surface of the base formation,wherein the first planar sheet includes an inner liner of an insulatingstructure. An insulating powder material is compacted to define apre-densified core material and the pre-densified core material ispositioned in engagement with an outward facing surface of the innerliner. A second planar sheet is formed to the shape of the pre-densifiedcore material, wherein the second planar sheet defines the outerwrapper. The outer wrapper and inner liner are sealed together to definean insulating cavity between the outer wrapper and the inner liner,wherein the pre-densified core material is disposed within theinsulating cavity to define the insulating structure. The insulatingstructure is then removed from the base formation.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of an appliance incorporating anaspect of the vacuum insulated structure formed according to at leastone aspect of the method described herein;

FIG. 2 is a schematic diagram illustrating a first process for formingthe vacuum insulated structure;

FIG. 3 is a schematic diagram illustrating a method for forming athree-dimensional insulating structure using an aspect of the coreinsulating powder;

FIG. 4 is a schematic diagram illustrating an aspect of a process forforming a three-dimensional insulated structure using the core powderinsulation;

FIG. 5 is a schematic diagram illustrating a process for forming thevacuum insulated structure utilizing a three-dimensional core insulationmember;

FIG. 6 is a schematic diagram illustrating an aspect of a method forforming a vacuum insulated structure utilizing a three-dimensionalinsulating core member;

FIG. 7 is a schematic flow diagram illustrating a method for forming aninsulated structure for an appliance;

FIG. 8 is a schematic flow diagram illustrating an aspect of a methodfor forming an insulated structure for an appliance; and

FIG. 9 is a schematic flow diagram illustrating an aspect of a methodfor forming an insulated structure for an appliance.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

As illustrated in FIGS. 1-6, reference numeral 10 generally refers to aninsulating structure that is incorporated within an appliance 12 forproviding an insulating functionality to various portions andcompartments of the appliance 12. According to the various embodiments,the insulating structure 10 can typically include an outer wrapper 14and an inner liner 16 that are sealed together and define an insulatingcavity 18 between the outer wrapper 14 and the inner liner 16. Aninsulating material 20 is disposed within the insulating cavity 18,where the insulating material 20 can take any one of various forms. Suchforms can be in a powder-type form of a core powder insulation 22, agranulated form of the core powder insulation 22, a pre-densified formof the core powder insulation 22, a densified three-dimensionalinsulating member 24 made of a core powder insulation 22, combinationsthereof, and other similar compacted forms of the core powder insulation22.

Referring now to FIGS. 2 and 7, a method 400 for forming an insulatingstructure 10 for an appliance 12 is disclosed. According to the method400, a structural enclosure, such as an insulating structure 10 thatincludes the outer wrapper 14 and inner liner 16 is formed (step 402).As discussed above, the insulating cavity 18 can be defined between theouter wrapper 14 and the inner liner 16. The core powder material, whichcan take the form of an insulating powder material 20, is formed (step404). It is contemplated that the insulating powder material 20 can bemade of various nano/micro-sized particulate material that can include,but is not limited to, powdered silica (fume or precipitated),granulated silica, other silica material, powder aerogel, hollow glassspheres, pearlite, rice husk ash, fly ash, silica fume, diatomaceousearth, carbon black and silicon carbide, combinations thereof, and othernano-sized and/or micro-sized particulate material. According to variousembodiments, the insulating powder material 20 is compacted to form apre-densified core material 26 (step 406). It is contemplated that thepre-densified core material 26 can take the form of a granulated aspectof the insulating powder material 20. The pre-densified core material 26can then be further prepared for deposition into an insulating structure10. Such further preparation can include mixing the pre-densified corematerial 26 with other additives and insulating materials 20 and alsodrying the pre-densified core material 26 to insure that substantiallyall of the fluid is evaporated or otherwise removed from thepre-densified core material 26. Such additives can include, but are notlimited to, hollow glass spheres, glass fibers, pearlite, rice husk ash,fly ash, silica fume, diatomaceous earth, carbon black and siliconcarbide, combinations thereof and other similar insulating additives.

Referring again to FIGS. 2 and 7, once the pre-densified core material26 is prepared, the pre-densified core material 26 is disposed withinthe insulating cavity 18 of the insulating structure 10 (step 408). Oncedisposed therein, the insulating structure 10 can be hermetically sealedand at least a portion of the gas 28 contained within the insulatingcavity 18 can be expressed through at least one vacuum port 30 (step410). In this manner, the hermetically sealed insulating structure 10forms a vacuum insulated structure 32.

Referring now to FIGS. 2-6, it is contemplated that the pre-densifiedcore material 26 can be positioned within the insulating cavity 18 andbetween the inner liner 16 and outer wrapper 14 before the outer wrapper14 and inner liner 16 are attached and/or sealed together. In such anembodiment, it is contemplated that the pre-densified core material 26can be disposed within the outer wrapper 14 and the inner liner 16 canbe placed thereon. The final compaction of the pre-densified corematerial 26 in this embodiment can occur as the inner liner 16 is placedwithin the outer wrapper 14, and the pre-densified core material 26 iscompressed to substantially conform to the shape of the insulatingcavity 18 defined between the outer wrapper 14 and the inner liner 16.

According to various alternate embodiments, it is contemplated that thepre-densified core material 26 can be disposed within the insulatingcavity 18 through an inlet port 40 defined in one of the outer wrapper14 and inner liner 16. In such an embodiment, it is contemplated thatthe pre-densified core material 26 is disposed within the insulatingcavity 18 after the outer wrapper 14 and inner liner 16 are attachedand, in certain embodiments, sealed together. It is also contemplatedthat a compaction of the pre-densified core material 26 into the finallycompacted three-dimensional insulating member 24 of the vacuuminsulating structure 10 can occur during expression of gas 28 from theinsulated cavity. In such an embodiment, the expression of gas 28 fromthe insulating cavity 18 can result in a negative compressive forcebeing exerted upon the pre-densified core material 26 to furthercompress the pre-densified core material 26 into a finally compactedthree-dimensional insulating member 24 disposed within the insulatingcavity 18. Where the pre-densified core material 26 is disposed in theinsulating cavity 18 via the inlet port 40, the compaction of thepre-densified core material 26 can be assisted through various vibratingand/or rotating mechanisms that serve to position the particles of thepre-densified core material 26 in a more densified state and throughoutthe insulating cavity 18. The vibrating and rotating mechanisms adjustthe positioning of the pre-densified core material 26 such that theinsulating structure 12 is shaken and rotated to manipulate thepre-densified core material 26 to occupy the entire insulating cavity18.

Referring now to FIGS. 3-6, according to various embodiments, it iscontemplated that the step of forming the structural enclosure caninclude wrapping a planar sheet 50 around a base formation 52. In suchan embodiment, the wrapped planar sheet 50 can take the form of theinner liner 16 such that the base formation 52 defines at least onecompartment of the appliance 12 defined by the inward facing surface 56of the inner liner 16. It is also contemplated that a base formation 52can include a forming cavity 58 within which the planar sheet 50 isdisposed. In these embodiments, the planar sheet 50 is formed within theforming cavity 58 to form the outer wrapper 14. It is contemplated thatwhere the base formation 52 is used, the insulating structure 10 canremain upon the base formation 52 at least until the pre-densified corematerial 26 is disposed within the insulating cavity 18 of theinsulating structure 10 and the inner liner 16 and outer wrapper 14 aresealed together.

Referring again to FIGS. 3 and 4, it is contemplated that thepre-densified core material 26 can take the form of a three-dimensionalinsulating member 24 that can be disposed as a single piece between theinner liner 16 and outer wrapper 14 of the insulating structure 10. Itis contemplated that in order to keep the three-dimensional shape of thethree-dimensional insulating member 24, the three-dimensional insulatingmember 24 can include at least one binder material 70. Such bindermaterials 70 can include, but are not limited to, various cellulosecompounds, wax, polyethylene glycol, gelatin, starch, polyvinyl alcohol,polymethacrylates, sodium silicates, combinations thereof, and othersimilar organic and inorganic materials that can be included within thepre-densified core material 26 to form and maintain the shape of thethree-dimensional insulating member 24. It is contemplated that thethree-dimensional insulating member 24 can be formed through acompaction of the pre-densified core material 26, or through compactionof the insulating powder material 20. It is further contemplated thatthe three-dimensional insulating member 24 can be made by compactingboth the pre-densified core material 26 and also the insulating powdermaterial 20 that have been mixed together to form a substantiallyuniform insulating material 20. It is contemplated that the use of botha pre-densified granular insulating material 72 and the insulatingpowder material 20 to be compacted to form the three-dimensionalinsulating member 24 can serve to allow the particles of the insulatingpowder material 20 to fit between the porous spaces defined between thelarger particles of the granular insulating material 72. In this manner,compaction of the insulating mixture made up of the insulating powdermaterial 20 and the pre-densified granular insulating material 72 can bea densified three-dimensional insulating member 24 having asubstantially consistent and uniform distribution of particles of theinsulating powder material 20 and the granular insulating material 72.

Referring again to FIGS. 3, 4 and 6, it is contemplated that after thethree-dimensional insulating member 24 or core member is formed, thethree-dimensional insulating member 24 can be bonded to one or both ofthe outer wrapper 14 and the inner liner 16. This bonding step can serveto minimize the amount of air spaces that may exist between thethree-dimensional core member and the outer wrapper 14 and the innerliner 16. The bonding step can be performed by welding, adhesives,bonding agents, combinations thereof and other similar methods andmaterials.

Referring again to FIGS. 1-6 and 8, a method 600 is disclosed forforming an insulated structure for an appliance 12. According to variousaspects of the method 600, a base formation 52 is provided where asurface 80 of the base formation 52 defines a shape of the insulatingstructure 10 or insulating enclosure (step 602). As discussed above, thebase formation 52 can be in the form of a positive volume around which aplanar sheet 50 is formed to define the inner liner 16. As alsodiscussed above, the base formation 52 can take the form of a formingcavity 58 within which a planar sheet 50 can be formed to define theouter wrapper 14. According to the method 600, a first planar sheet 90can be formed to the surface 80 of the base formation 52 (step 604). Itis contemplated that the first planar sheet 90 can be formed to defineeither the outer wrapper 14 or the inner liner 16 of the insulatingstructure 10. As discussed above, the insulating powder material 20 canbe compacted to define a pre-densified core material 26 (step 606). Thepre-densified core material 26 can take the form of a granularinsulating material 72 where various portions of the insulating powdermaterial 20 are compacted into larger granular sized pieces ofinsulating material 20. The sizes of the particles of the pre-densifiedcore material 26 and the granular sizes of the insulating material 20can vary. By way of example, and not limitation, such particle and/orgranule sizes can range from approximately 250 microns to approximately5000 microns. It is contemplated that smaller particle sizes and largergranule sizes can be implemented. In order to maintain the size andshape of the granular insulating material 72, the particles of thegranular insulating material 72 can be combined with the binder material70 that provides each granule of the granular insulating material 72with greater compressive strength than various granules without thebinder material 70. It is also contemplated that the pre-densified corematerial 26 can take the form of a three-dimensional insulating member24, where the three-dimensional insulating member 24 can include one ormore of the binder materials 70 to maintain the shape of thethree-dimensional insulating member 24. In this manner, the bindermaterials 70 allow the three-dimensional insulating member 24 to behandled more easily without substantially disintegrating, degrading, orotherwise becoming damaged. It is further contemplated that thethree-dimensional insulating member 24 can be wrapped in a high barriermetallized film 74 having one or more layers or other membrane to allowthe three-dimensional insulating member 24 to be handled withoutsubstantial damage.

Referring again to FIGS. 3-6 and 8, the pre-densified core material 26can be positioned in engagement with the formed first planar sheet 90(step 608). As discussed above, where the pre-densified core material 26is a granular insulating material 72, the granular insulating material72 can be poured into the outer wrapper 14 and the inner liner 16 placedon top. The inner liner 16 and outer wrapper 14 can be pressed togethersuch that the granular insulating material 72 is compacted further toform the three-dimensional insulating member 24 by pressing the innerliner 16 into the outer wrapper 14, thereby compressing thepre-densified core material 26. Alternatively, where the pre-densifiedcore material 26 is a three-dimensional insulating member 24, it iscontemplated that the three-dimensional insulating member 24 can beeither placed over the inner liner 16, or placed within the outerwrapper 14. Once the pre-densified core material 26 is placed withinengagement of the first planar sheet 90, a second planar sheet 92 isformed substantially to the shape of the three-dimensional insulatingmember 24 and placed against the pre-densified core material 26. It iscontemplated that the second planar sheet 92 can include the other ofthe outer wrapper 14 and inner liner 16 that engages the first planarsheet 90 formed on the surface 80 of the base formation 52 (step 610).The outer wrapper 14 and inner liner 16 can then be sealed together todefine an insulating cavity 18 between the outer wrapper 14 and theinner liner 16 (step 612). It is contemplated that the pre-densifiedcore material 26 is disposed within the insulating cavity 18 between theinner liner 16 and the outer wrapper 14. At least a portion of the gas28 contained within the insulating cavity 18 can be expressed from theinsulating cavity 18 (step 614). It is contemplated that the insulatingcavity 18 can then be hermetically sealed to define the vacuum insulatedstructure 32 with the compacted and pre-densified core material 26disposed therein.

Referring again to FIGS. 3-6, where the first planar sheet 90 definesthe outer wrapper 14, the pre-densified core material 26 can be disposedwithin a wrapper volume 98 defined by an interior surface 100 of theouter wrapper 14. As discussed above, in such an embodiment, thepre-densified core material 26 can take the form of the granularinsulating material 72 for the three-dimensional insulating member 24.Once disposed within the wrapper volume 98, the inner liner 16 can beplaced over the outer wrapper 14 such that the granular insulatingmaterial 72 can be compacted, or such that the three-dimensionalinsulating member 24 can be disposed in the insulating cavity 18 betweenthe inner liner 16 and the outer wrapper 14.

Referring again to FIGS. 5 and 6, where the first planar sheet 90 is theinner liner 16, the pre-densified core material 26, typically in theform of a three-dimensional insulating member 24, is disposed against anoutward facing surface 110 of the inner liner 16. In this manner, thethree-dimensional insulating member 24 surrounds the outward facingsurface 110 of the inner liner 16 such that the outer wrapper 14 can beplaced over the three-dimensional insulating member 24 and sealed withthe inner liner 16 to form the insulating cavity 18 and, in turn, theinsulating structure 10. It is contemplated that in such an embodiment,the three-dimensional core member can be bonded to at least the outwardfacing surface 110 of the inner liner 16. The three-dimensionalinsulating member 24 can also be bonded to the outer wrapper 14proximate the insulating cavity 18.

According to the various embodiments of the methods described herein,the insulating powder material 20 is disposed into direct engagementwith the inner liner 16 and the outer wrapper 14. This is the casewhether the insulating powder material 20 is in powder form, granularform, or in the form of the three-dimensional insulating member 24. Inthis manner, the vacuum insulated structure 32 can be formed without theuse of barrier films or porous bags that may separate the insulatingmaterial 20 from the inner liner 16 and/or the outer wrapper 14.

Referring again to FIGS. 2-6 and 9, a method 800 is disclosed forforming an insulated structure for an appliance 12. According to themethod 800, a base formation 52 is provided, where a surface 80 of thebase formation 52 defines a shape of an insulating structure 10 orinsulating enclosure (step 802). According to the method 800, a firstplanar sheet 90 is formed at the surface 80 of the base formation 52,where the first planar sheet 90 defines the inner liner 16 of theinsulating structure 10 (step 804). The insulating powder is thencompacted to define the pre-densified core material 26 (step 806). Asdiscussed above, the pre-densified core material 26 can be compacted inthe form of a three-dimensional insulating member 24 or in the form of agranular insulating material 72. The three-dimensional insulating member24 can be in the form of a contoured shape that conforms to the shape ofa portion of the inner liner 16 and/or the outer wrapper 14. Thethree-dimensional insulating member 24 can also be in the form of aninsulating panel that is generally rectilinear and/or cuboidal inconfiguration. According to the method 800, the pre-densified corematerial 26 is then positioned in engagement with an outward facingsurface 110 of the inner liner 16 (step 808). In such an embodiment, thepre-densified core material 26 will, typically, take the form of athree-dimensional insulating member 24. In this manner, thethree-dimensional insulating member 24 can be placed over the outwardfacing surface 110 of the inner liner 16 and the three-dimensionalinsulating member 24 can maintain its shape, or substantially maintainits shape, during formation of the insulating structure 10. A secondplanar sheet 92 is then formed to define the outer wrapper 14.

According to various embodiments, the outer wrapper 14 can be formedagainst a separate base formation 52, or can be formed around a portionof the pre-densified core material 26 (step 810). It is contemplatedthat the inner liner 16 and outer wrapper 14 can take the form of ametal panel that is shaped, pressed, punched, or otherwise manipulatedto take the form of the inner liner 16 and/or the outer wrapper 14. Itis further contemplated that the inner liner 16 and outer wrapper 14 canbe made of a polymer-type material. In such an embodiment, thepolymer-type material can be blow molded, vacuum formed, thermoformed,injection-molded, compression molded, or otherwise shaped to form theinner liner 16 and/or the outer wrapper 14. Where a plastic-typematerial is used, the outer wrapper 14 and the inner liner 16 caninclude various barrier layers or films that can vary depending on thedesign of the insulating structure 10 and the insulating requirementsthereof.

According to the method 800, as exemplified in FIGS. 2-6 and 9, afterthe outer wrapper 14 is placed over the pre-densified core material 26and the inner liner 16, the outer wrapper 14 and inner liner 16 aresealed together to define the insulating cavity 18 (step 812). In thismanner, the pre-densified core material 26 is contained within theinsulating cavity 18 to define the insulating structure 10 for theappliance 12. After the insulating structure 10 is formed, it iscontemplated that the insulating structure 10 can be removed from thebase formation 52 (step 814). It is also contemplated that theinsulating structure 10 can be removed from the base formation 52 aftergas 28 is expressed from the insulating cavity 18 and the vacuuminsulated structure 32 is formed. As such, the expressing step can beperformed while the insulating structure 10 is engaged with the baseformation 52 and removed after the vacuum insulating structure 10 isformed.

According to the various embodiments, aspects of the step 806 ofcompacting the insulating powder material 20 and/or the granularinsulating material 72 into the three-dimensional insulating member 24or 2D VIP or 2D core panels can be performed either between the innerliner 16 and outer wrapper 14, or can be performed in a separatepressing assembly 116 where the insulating material 20 is disposedwithin a compression cavity 118 and a compression member 120 is disposedwithin the compression cavity 118 to compress the insulating material 20into the three-dimensional insulating member 24. It is contemplated thatthe binder material 70 can be disposed within the compression cavity 118and mixed in with the insulating material 20 such that when thethree-dimensional insulating member 24 is formed, the binder material 70substantially retains the three-dimensional insulating member 24 in itsshape for removal from the compression cavity 118 and placement oneither the inner liner 16 or within the outer wrapper 14 to form theinsulating structure 10.

It is contemplated that the various aspects of the devices and methodsdescribed herein can be utilized to form various insulating forms thatinclude, but are not limited to, three-dimensional insulating members24, insulating panels, planar core members, plural and contouredthree-dimensional vacuum insulated panels, and others. It is alsocontemplated that the insulating member or members formed using theaspects of the device can be used within various appliances 10. Suchappliances 10 can include, but are not limited to, refrigerators,freezers, warmers, ovens, dishwashers, laundry appliances, waterheaters, furnaces, and other similar appliances.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A method of forming an insulated structure for anappliance, the method comprising steps of: compacting a silica-basedinsulating powder material to form a pre-densified core material;positioning the pre-densified core material between inner and outerpanels, wherein an insulating cavity is defined between the inner andouter panels; and sealing the inner and outer panels to contain thepre-densified core material within the insulating cavity to define theinsulated structure.
 2. The method of claim 1, wherein the pre-densifiedcore material is a silica-based granular insulating material, andwherein the silica-based insulating powder material includes at leastone of fumed silica and precipitated silica.
 3. The method of claim 1,wherein the inner and outer panels define an inner liner and an outerwrapper, respectively, and the pre-densified core material is positionedbetween the inner liner and the outer wrapper before the outer wrapperand the inner liner are attached together.
 4. The method of claim 3,wherein the pre-densified core material is a three-dimensional coremember.
 5. The method of claim 4, wherein the three-dimensional coremember is bonded to at least one of the outer wrapper and the innerliner.
 6. The method of claim 1, wherein the pre-densified core materialis a three-dimensional core member that includes at least one bindermaterial, wherein the binder material includes at least one ofcellulose, wax, polyethylene glycol, gelatin, starch, polyvinyl alcohol,polymethacrylate and sodium silicate.
 7. The method of claim 1, whereinthe step of compacting the silica-based insulating powder material toform the pre-densified core material is at least partially performedbetween the inner and outer panels.
 8. The method of claim 7, wherein atleast a portion of the step of compacting the silica-based insulatingpowder material includes placing the silica-based insulating powdermaterial against the outer panel and compressing the silica-basedinsulating powder material with the inner panel.
 9. The method of claim7, wherein the step of compacting the silica-based insulating powdermaterial is performed while expressing at least a portion of gas fromthe insulating cavity, wherein the silica-based insulating powdermaterial directly engages the inner and outer panels.
 10. The method ofclaim 1, wherein the step of positioning the pre-densified core materialincludes wrapping an inner panel around a base formation, wherein theinner panel forms an inner liner, wherein the inner panel remains on thebase formation at least until the pre-densified core material isdisposed within the insulating cavity.
 11. A method of forming aninsulated structure for an appliance, the method comprising steps of:providing a base formation, wherein a surface of the base formationdefines a shape of an insulating enclosure; forming a first planar sheetto the surface of the base formation; compacting a silica insulatingpowder material to define a pre-densified core material; positioning thepre-densified core material in engagement with the first planar sheet;forming a second planar sheet against the pre-densified core material;and sealing the first and second planar sheets together to define aninsulating cavity between the first and second planar sheets, whereinthe pre-densified core material is disposed within the insulatingcavity.
 12. The method of claim 11, further comprising a step of:expressing at least a portion of a gas contained within the insulatingcavity, wherein the first and second planar sheets and the pre-densifiedcore material at least partially define a vacuum insulated structure.13. The method of claim 11, wherein the pre-densified core material isdisposed within a wrapper volume defined by an interior surface of thefirst planar sheet.
 14. The method of claim 11, wherein thepre-densified core material is in a form of a partially compactedgranular insulating material.
 15. The method of claim 11, wherein thestep of compacting the silica insulating powder material to define thepre-densified core material is performed while the silica insulatingpowder material is within the insulating cavity, and wherein thepre-densified core material is in a form of a three-dimensionalinsulating member.
 16. The method of claim 15, wherein thethree-dimensional insulating member is bonded to an inward facingsurface of the first planar sheet, wherein the inward facing surface atleast partially defines the insulating cavity.
 17. The method of claim12, wherein the vacuum insulated structure is free of a barrier filmdisposed in the insulating cavity.
 18. An insulated structure for anappliance, the insulated structure comprising: a first planar sheet thatdefines a predetermined contoured shape that is configured to correspondto a base formation; a pre-densified core member that includes acompacted and silica-based insulating powder, wherein the pre-densifiedcore member is in direct engagement with an outward facing surface ofthe first planar sheet; and a second planar sheet that is formed againstthe pre-densified core member, wherein the first and second planarsheets are sealed together to define an insulating cavity having thepre-densified core member disposed therein.
 19. The insulated structureof claim 18, wherein the insulating cavity defines an at least partialvacuum and the first and second planar sheets and the pre-densified coremember define a vacuum insulated structure.
 20. The insulated structureof claim 19, wherein the vacuum insulated structure is free of a barrierfilm disposed in the insulating cavity.